Filter for a Smoking Article

ABSTRACT

The invention relates to a filter ( 1 ) for a smoking article, a method of production thereof, a smoking article and a device for inserting a first fibrous filter material ( 3 ) into a second fibrous filter material ( 4 ) to form a filter for a smoking article. Particularly but not exclusively the invention relates to a smoking article filter segment including a region of first fibrous filter material ( 3 ) disposed within a region of second fibrous filter material ( 4 ) and a method of production thereof. The first fibrous filter material ( 3 ) in some embodiments comprises greater than 5% by volume of the total filter segment volume and in some embodiments the first fibrous material comprises PLA fibres and the second fibrous filter material comprises CA fibres.

TECHNICAL FIELD

The invention relates to a filter for a smoking article, a method ofproduction thereof, a smoking article and a device for inserting a firstfibrous filter material into a second fibrous filter material to form afilter for a smoking article. Particularly but not exclusively theinvention relates to a filter for a smoking article including a regionof first fibrous filter material disposed at least substantially withina region of second fibrous filter material, a smoking article includingsuch a filter and a method and device for the production thereof.

BACKGROUND

It is known to use cellulose acetate fibres, plasticised with anadditive such as triacetin, in cigarette filters. It is also known touse certain other fibrous materials, for instance cotton or paper basedmaterials, as an alternative to cellulose acetate in cigarette filters.

SUMMARY

In accordance with embodiments of the invention, there is provided afilter segment for a smoking article, the filter segment comprising aregion of first fibrous filter material disposed at least substantiallywithin a region of second fibrous filter material, wherein the firstfibrous filter material comprises greater than 5% by volume of the totalfilter segment volume.

The first fibrous filter material can be disposed in a plurality ofregions of the filter segment. The plurality of regions can eachcomprise greater than 3% of the total filter segment volume.

The second fibrous filter material can be a plasticised filter materialand the first fibrous filter material can be a non-plasticised filtermaterial.

The first and second fibrous filter materials can comprise crimpedfibres.

The first fibrous filter material can comprise polylactide (PLA) fibresand/or the second fibrous filter material can comprise cellulose acetatefibres.

The first fibrous filter material can comprise from 5 to 60% by volumeof the total filter segment volume.

The first fibrous filter material can comprise from 10 to 20% by volumeof the total filter segment volume.

The first fibrous filter material can comprise from 200 to 10,000 fibreshaving a denier from 2 to 10 denier per filament.

The region of first fibrous filter material can comprise a regionextending longitudinally through the region of second fibrous filtermaterial.

In accordance with embodiments of the invention, there is also provideda filter segment for a smoking article, the filter segment comprising aregion of first fibrous material disposed at least substantially withina region of second fibrous material, wherein the first fibrous materialcomprises polylactide (PLA) fibres.

The second fibrous material can comprise cellulose acetate (CA) fibres.

In accordance with embodiments of the invention, there is also provideda smoking article comprising a filter segment as set out above.

In accordance with embodiments of the invention, there is furtherprovided a method of producing a filter segment for a smoking article,the method comprising feeding a supply of a first fibrous filtermaterial into a second fibrous filter material to form a filter segmentas set out above.

The method can further comprise applying a plasticiser to said secondfibrous filter material prior to feeding the supply of the first fibrousmaterial into the second fibrous filter material.

The method can further comprise crimping said first and second fibrousfilter materials prior to feeding the supply of the first fibrousmaterial into the second fibrous filter material.

The method can further comprise compressing said second fibrous filtermaterial to form a filter rod and feeding the supply of the firstfibrous filter material into the second fibrous filter material whilecompressing the second fibrous filter material to form the filter rod.

The first fibrous filter material can be fed into the second filtermaterial in a tongue section of a filter making apparatus. The firstfibrous filter material can comprise a thread of first fibrous filtermaterial.

In accordance with embodiments of the invention, there is furtherprovided a method of producing a filter for a smoking article, themethod comprising generating a fluid stream and transferring a firstfibrous material along a transfer path into a flow of a second fibrousfilter material using the fluid stream.

The fluid stream can be generated using air pressure.

The first fibrous filter material can be transferred into the flow ofthe second fibrous filter material in a tongue or stuffer jet section ofa filter making apparatus.

In accordance with embodiments of the invention, there is furtherprovided a device for inserting a first fibrous filter material into asecond fibrous filter material to form a filter for a smoking article,the device comprising a pressure generator to generate a fluid streamfor carrying said first fibrous material along a transfer path into aflow of said second fibrous filter material.

In accordance with embodiments of the invention, there is furtherprovided a filter for a smoking article, as herein described withreference to the accompanying drawings.

In accordance with embodiments of the invention, there is furtherprovided a smoking article as herein described with reference to theaccompanying drawings.

In accordance with embodiments of the invention, there is furtherprovided a fibrous material insertion device as herein described withreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of exampleonly, with reference to the accompanying drawings, in which:

FIGS. 1( a) to 1(e) are schematic illustrations of smoking articlesincluding filter segments according to embodiments of the invention;

FIG. 2 is a schematic illustration of a first device for inserting afirst fibrous filter material into a second fibrous filter material toproduce a filter segment such as those of the smoking articlesillustrated in FIGS. 1( a) to 1(d);

FIG. 3 is a schematic side view of a section of the device of FIG. 2;

FIG. 4 is a schematic rear view of a section of the device of FIG. 2;

FIG. 5 is a schematic illustration of a second device for inserting afibrous filter material into a second fibrous filter material to producea filter segment such as those of the smoking articles illustrated inFIGS. 1( a) to 1(d);

FIG. 6 is a schematic side view of a section of the device of FIG. 5;

FIG. 7 is a schematic rear view of a section of the device of FIG. 5;

FIG. 8 is a schematic illustration of a third device according to anembodiment of the invention for inserting a first fibrous filtermaterial into a second fibrous filter material to produce a filtersegment such as that of the smoking article illustrated in FIG. 1( a);

FIG. 9 is a cross sectional schematic view of the device of FIG. 8;

FIG. 10 is a cross sectional view of the venture device shown in FIGS. 8and 9;

FIG. 11 is a schematic illustration showing the operation of the venturidevice of FIGS. 8, 9 and 10;

FIG. 12 is a cross sectional schematic view of a fourth device accordingto a further embodiment of the invention for inserting a first fibrousfilter material into a second fibrous filter material to produce afilter segment such as that of the smoking article illustrated in FIG.1( a);

FIG. 13 is a schematic illustration of a fifth device according to afurther embodiment of the invention for inserting a first fibrous filtermaterial into a second fibrous filter material to produce a filtersegment such as those of the smoking articles illustrated in FIGS. 1( a)to 1(d); and

FIG. 14 is a schematic illustration of a sixth device according to afurther embodiment of the invention for inserting a first fibrous filtermaterial into a second fibrous filter material to produce a filtersegment such as that illustrated in FIG. 1( e).

DETAILED DESCRIPTION

FIGS. 1( a) to 1(e) are schematic illustrations of smoking articlesincluding filter segments according to embodiments of the invention.

As used herein, the term “smoking article” includes smokeable productssuch as cigarettes, cigars and cigarillos whether based on tobacco,tobacco derivatives, expanded tobacco, reconstituted tobacco or tobaccosubstitutes and also heat-not-burn products.

Referring to FIG. 1( a), a first smoking article 1 includes a filtersegment 2 having a region of first fibrous filter material 3 disposedsubstantially within a region of second fibrous filter material 4. Inthe first smoking article 1, the filter segment 2 forms a mono filterhaving an overall cylindrical shape, with the first fibrous filtermaterial 3 disposed within a substantially cylindrically shaped coreregion of the second fibrous filter material 4, which forms an outer,hollow cylindrically shaped region of the filter segment 2. The firstfibrous filter material 3 accordingly extends axially through the lengthsecond fibrous filter material 4, being in the present example exposedonly at each end of the mono filter.

The filter segment 2 of the first smoking article 1 is wrapped in a plugwrap material 5 and connected to a tobacco rod 6 using a tippingmaterial 7 to form the first smoking article 1, in the present example acigarette.

Referring to FIG. 1( b), a second smoking article 11 includes a filtersegment 12 having first and second regions of a first fibrous filtermaterial 13 a, 13 b disposed substantially within a region of secondfibrous filter material 14. In the second smoking article 11, the filtersegment 12 forms a mono filter having an overall cylindrical shape, withthe first fibrous filter material 13 a, 13 b disposed within first andsecond regions of the second fibrous filter material 14. The first andsecond regions extend longitudinally through the length of the secondfibrous filter material 14, being in the present example exposed fromthe second fibrous filter material 14 only at each end of the monofilter. The first and second regions of first fibrous filter material 13a, 13 b are substantially cylindrical in shape. In the present example,the first and second regions of first fibrous filter material 13 a, 13 bare diametrically spaced apart from each other and from the outerlongitudinal periphery of the second fibrous filter material 14.

The filter segment 12 of the second smoking article 11 is wrapped in aplug wrap material 15 and connected to a tobacco rod 16 using a tippingmaterial 17 to form the second smoking article 11, in the presentexample a cigarette.

Referring to FIG. 1( c), a third smoking article 21 includes a filtersegment 22 having a plurality of regions of first fibrous filtermaterial 23 a-23 d disposed substantially within a second fibrous filtermaterial 24. In the third smoking article 21, the filter segment 22forms a mono filter having an overall cylindrical shape, with the firstfibrous filter material 23 a-23 d disposed within first to fourthregions. Each of the four regions of first fibrous filter material 23a-23 d extends longitudinally through the length second fibrous filtermaterial 24, being in the present example exposed from the secondfibrous filter material 24 only at each end of the mono filter. Theregions of first fibrous filter material 23 a-23 d are substantiallycylindrical in shape. In the present example, the regions of firstfibrous filter material 23 a-23 d are annularly disposed within thesecond filter material 24 and spaced at 90° from each other and from theouter longitudinal periphery of the second fibrous filter material 24.

The filter segment 22 of the third smoking article 21 is wrapped in aplug wrap material 25 and connected to a tobacco rod 26 using a tippingmaterial 27 to form the third smoking article 21, in the present case acigarette.

Referring to FIG. 1( d), a fourth smoking article 31 includes a filtersegment 32 having a plurality of regions of first fibrous filtermaterial 33 a-33 e disposed substantially within a region of secondfibrous filter material 34. In the example of FIG. 1( d), the filtersegment 32 forms a mono filter having an overall cylindrical shape, withthe first 10 o fibrous filter material 33 a-23 e disposed within firstto fifth regions. Each of the five regions of first fibrous filtermaterial 33 a-33 e extends longitudinally through the length of thesecond fibrous filter material 34, being in the present example exposedfrom the second fibrous filter material 34 only at each end of the monofilter. The regions of first fibrous filter material 33 a-33 e aresubstantially cylindrical in shape. In the present example, the first tofourth regions of first fibrous filter material 33 a-33 d are annularlydisposed within the second filter material 34 and spaced at 90° fromeach other and from the outer longitudinal periphery of the secondfibrous filter material 34. The fifth region of first fibrous filtermaterial 33 e is disposed within a substantially cylindrically shapedcore of the second fibrous filter material 34.

The filter segment 32 is wrapped in a plug wrap material 35 andconnected to a tobacco rod 36 using a tipping material 37 to form thethird smoking article 31, in the present case a cigarette.

Referring to FIG. 1( e), a fifth smoking article 161 includes a filtersegment 162 having a plurality of regions of first fibrous filtermaterial 16 a-163 b disposed substantially within a region of secondfibrous filter material 164. In the example of FIG. 1( e), the filtersegment 162 forms a mono filter having an overall cylindrical shape,with the first fibrous filter material 163 a-163 b disposed within firstand second regions. Each of the first and second regions of firstfibrous filter material 163 a-163 b forms an elongate sector of thecylindrical filter, and extends longitudinally through the length of thesecond fibrous filter material 164, being in the present example exposedfrom the second fibrous filter material 164 at each end of the monofilter and along the length of first and second outer portions 165 a,165 b of the longitudinal surface of the cylindrical filter segment 162.

The regions of first fibrous filter material 163 a-163 b have thesubstantial shape of elongate sectors in the present example. Also, thefirst and second regions of first fibrous filter material 163 a-163 bare disposed within the second filter material 164 spaced at 180° fromeach other. However, alternatively only one region of first fibrousfilter material 163 can be used, or three or more regions of firstfibrous filter material 163 can be used, spaced evenly or unevenlyaround the filter segment 162. Also, the shape of the regions of firstfibrous filter material, whether one, two, three or more regions, is notlimited to an elongate sector, and could be shaped substantially to havethe form of an elongate quadrilateral, such as a rectangle and/oroblong.

The filter segment 162 is wrapped in a plug wrap material 166 andconnected to a tobacco rod 167 using a tipping material 168 to form thefifth smoking article 161, in the present case a cigarette.

In the first to fifth smoking articles 1, 11, 21, 31, 161, the firstfibrous filter material 3, 13, 23, 33, 163 comprises a non-plasticisedfilter material, in the present case polylactide (also referred to aspoly(lactic acid) or PLA) fibres. Such fibres are commerciallyavailable, for instance from companies such as Natureworks LLC in the USor Mitsui Chemical in Japan. Suitable fibres can be formed in processessuch as electrospinning, as would be known to those skilled in the art.The second fibrous filter material 4, 14, 24, 34, 164 comprises aplasticised filter material, in the present case cellulose acetate(hereinafter ‘CA’) fibres plasticised using triacetin (also referred toas glycerin triacetate).

Use of both the first and the second fibrous filter materials in asingle filter segment can enable the smoking article filter to benefitfrom properties of both materials. For instance, the first and secondfilter materials may each have greater selectivity in the filtration ofcertain smoke constituents than the other material. One or other of thefirst and second filter materials may be cheaper to produce or comprisea more sustainable base material than the other filter material. Forexample, PLA is generally considered to be a more sustainable filtermaterial than CA, although plasticised CA can have a greater filtrationselectivity to certain smoke constituents than PLA, for instancephenols.

A limitation of PLA fibres and other non-cellulose acetate based fibrematerials can be that the fibres are relatively soft and that certain CAfilter plasticisers such as triacetin, polyethylene glycol (PEG) andtriethyl citrate (TEC), usually used to increase the firmness of CAfilters, are not sufficiently effective at increasing the firmness ofthe non-cellulose acetate material or mixtures of the non-celluloseacetate material with CA. Accordingly, such filters may not be providedwith an appropriate rigidity and/or hardness for use in/as smokingarticle filters. The filter segment structures provided in the first tofourth smoking articles 1, 11, 21, 31, 161 of FIGS. 1( a) to 1(e) andother embodiments of the invention can overcome such limitations byenabling a first filter material such as PLA fibres to be heldsubstantially within the structure of a second filter material such asCA fibres. The second filter material such as CA fibres can, forinstance, be plasticised to provide an appropriate rigidity and/orhardness to the overall filter segment 2, 12, 22, 32, 162.

Other suitable materials for the first fibrous filter material includepaper or paper-based materials, polyvinyl alcohol (PVOH) or PVOH basedmaterials, starch-based materials, reconstituted tobacco materials,extruded materials or other fibrous filter materials, for instance thosewhich cannot be readily plasticised by a cellulose acetate plasticiser(although the invention is not limited to the use of such materials).

Other suitable materials for the second fibrous filter material includepaper or paper-based materials, polyvinyl alcohol (PVOH) or PVOH basedmaterials, starch-based materials, reconstituted tobacco materials,extruded materials or other fibrous filter materials.

The first and/or second fibrous filter material can be coloured and/orinclude an additive such as a flavourant, for instance menthol or coffee(where local regulations permit the use of such flavourants) or anadsorbent such as activated carbon granules or an ion exchange resin,giving the filter segment unique flavouring or filtration properties,and/or a unique end appearance.

Including the first fibrous filter material in one or more regionssubstantially within the second fibrous filter material can enable thesecond fibrous filter material to be plasticised, or cured, with thefirst fibrous filter material inserted into the one or more regionsduring the manufacturing process, for instance after a plasticiser hasbeen applied to the second filter material. This can help to locate thefirst filter material into a desired position within the second filtermaterial, which can have the associated advantage of improving the endappearance of the filter.

In each of the first to fifth smoking articles 1, 11, 21, 31, 161illustrated in FIGS. 1( a) to 1(e), the first fibrous filter material 3,13, 23, 33, 163 can, for instance, comprise from 5% to 70% of the totalfilter segment volume. The fibres of the first filter material, in thepresent examples PLA fibres, can, for instance, have a filament denierof from 2 to 10, more particularly from 2 to 7, and can be formed using,for instance, between 200 and 10,000 fibres per region in which they arelocated. The fibres of the second filter segment, in the presentexamples CA fibres, can have a filament denier of from 2 to 10, moreparticularly from 2 to 7, and between 5,000 and 20,000 fibres can, forinstance, be used to form the filter. Appropriate fibre deniers andnumbers of filaments for each of the first and second filter materialscan be selected according to various factors, such as the crimp appliedto either or each of these materials, the desired ratio of the volumesof these materials, the desired total denier for the filter, the desiredpressure drop and or hardness for the filter, apparatus capabilities anddesired apparatus operating speeds. The second fibrous filter materialcan be plasticised with triacetin, or another plasticiser, used in anamount from, for instance, 5% to 12% by weight of the plasticisedfibres.

The filter segment 2 of FIG. 1( a) includes 10% by volume of the firstfibrous filter material 3, in that example PLA, and 90% by volume ofplasticised CA, in which triacetin accounts for 8% by weight of the CA.

The filter segment 12 of the second smoking article 11 illustrated inFIG. 1( b) includes 12% by volume of the first fibrous filter material13, in that example PLA, and 88% by volume of the second fibrous filtermaterial 14, in that case plasticised CA, in which triacetin accountsfor 8% by weight of the CA. Each region of the first fibrous filtermaterial 13 comprises 6% of the total filter segment volume.

The filter segment 22 of the third smoking article 21 illustrated inFIG. 1( c) includes 16% by volume of the first fibrous filter material23, in that example PLA, and 84% by volume of the second fibrous filtermaterial 24, in that case plasticised CA, in which triacetin accountsfor 8% by weight of the CA. Each of the four regions of the firstfibrous filter material comprises 4% of the total filter segment volume.

The filter segment 32 of the fourth smoking article 31 illustrated inFIG. 1( d) includes 20% by volume of the first fibrous filter material33, in that example PLA, and 80% by volume of the second fibrous filtermaterial 34, in that case plasticised CA, in which triacetin accountsfor 8% by weight of the CA. Each of the five regions of the firstfibrous filter material 33 comprises 4% of the total filter segmentvolume.

The filter segment 162 of the fifth smoking article 161 illustrated inFIG. 1( e) includes 40% by volume of the first fibrous filter material163, in that example PLA, and 60% by volume of the second fibrous filtermaterial 164, in that case plasticised CA, in which triacetin accountsfor 8% by weight of the CA. Each of the first and second regions 163 a,163 b of the first fibrous filter material 163 comprises 20% of thetotal filter segment volume.

Alternative relative volumes of the first and second fibrous filtermaterials can be used, and these will depend on the chosen materials,the fibre denier of the materials, the number of filaments used, and thelevel of crimp which is applied to each material. The volume of thefirst fibrous material can, for instance, comprise up to 20, 25, 30, 35,40, 45, 50, 55, 60, 65 or 70% of the total filter segment volume. Thefirst fibrous material can also be used in lower volumes, for instancedown to 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4.5, 4, 3.5, 3, 2.5, 2,1.5 or 1% of the total filter segment volume. The volume of the firstfibrous material can, accordingly, fall within a range comprising fromone of 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4.5, 4, 3.5, 3, 2.5, 2,1.5 or 1% of the total filter segment volume up to one of 20, 25, 30,35, 40, 45, 50, 55, 60, 65 or 70% of the total filter segment volume, inparticular from 10% to 70% of the total filter segment volume.

Each of the regions of first fibrous filter material can comprisegreater than 2%, greater than 2.5%, greater than 3%, greater than 3.5%,greater than 4% or greater than 5% of the total filter segment volume,for instance from 2%, 3%, 4% or 5% to 20%, 25% or 30% of the totalfilter segment volume.

The first fibrous filter material 3, 13, 23, 33 in the first to fourthsmoking articles is disposed in one or more regions spaced from theouter longitudinal periphery of the second fibrous filter material 4,14, 24, 34, such that the first fibrous filter material 3, 13, 23, 33 ispresent at the outer surface of the cylinder (or other shape) formed bythe first and second filter materials only at each end of the filtersegment. However, alternatively, the first fibrous filter material 3,13, 23, 33 in the first to fourth smoking articles can be disposed in aregion part of the boundary of which is coexistent with the outerperiphery of the filter segment formed by the first and second filtermaterials such that the first fibrous filter material is present at theouter surface of the filter segment at each end of the filter segmentand/or at one or more parts of the outer longitudinal periphery of thefilter segment (such latter surfaces being in contact with a plug wrapin the present examples).

The first fibrous filter material 3, 13, 23, 33, 163 in the first tofifth smoking articles is disposed such that it is at the outer boundaryof the respective filter segments 2, 12, 22, 32, 162 at each end of thefilter segments. However, alternatively, the first fibrous filtermaterial 3, 13, 23, 33, 163 can be disposed in at least one region whichis not at the outer boundary of the second fibrous filter material 4,14, 24, 34, 164 at either end of the respective filter segment or whichis at the outer boundary of the filter segment at one but not both endsof the filter segment.

The first fibrous filter material 3, 13, 23, 33, 163 in the first tofifth smoking articles is disposed in up to five separate regions.However, the first fibrous filter material 3, 13, 23, 33, 163 can bedisposed in greater than five regions, such as 6, 7, 8, 9, 10, 11 or 12regions, so as to provide a desired volume or weight of the firstfibrous filter material 3, 13, 23, 33, 163 within the filter segment 2,12, 22, 32, 162.

As used herein, the term filter segment refers to a single discretefilter component which can be individually attached to a smokingarticle. The filter segments 2, 12, 22, 32, 162 used in the first tofifth smoking articles 1, 11, 21, 31, 161 are mono filter segments,comprising the entire filter for such smoking articles 1, 11, 21, 31,161. However, the filter segments 2, 12, 22, 32, 162 can alternativelybe used in other filter configurations, such as the mouth end, tobaccoend or both segments of a dual, dual dalmatian or cavity filters, or oneor more of the mouth end, intermediate and tobacco end segments of atriple or quad filter. One or more of the segments of the filter maycomprise non-wrapped acetate (NWA) segments.

The first and/or second fibrous filter materials 3, 4, 13, 14, 23, 24,33, 34, 163, 164 can comprise mixtures of different materials, forinstance mixtures of fibres of a plurality of materials or the fibresthemselves being formed from blends or composites of a plurality ofmaterials.

FIGS. 2 to 4 are schematic illustrations of a first device 40 forinserting a first fibrous filter material into a second fibrous filtermaterial to produce a filter segment such as those of the smokingarticles illustrated in FIGS. 1( a) to 1(d). Such a device is describedin more detail in International patent publication WO2010/108739, thecontents of which are expressly incorporated herein by reference, andcan be adapted for use in producing filter segments according to thepresent invention in the manner set out below.

The first device 40, in use, is connected to a filter making apparatussuch as the KDF 2 apparatus produced by Hauni Maschinenbau AG in Germanyand is capable of producing a filter rod with up to five separateregions of a first fibrous filter material extending through thecross-section of the filter formed from a second fibrous filtermaterial. The first device 40 comprises a tongue 41 having a wideentrance opening 41 b and a narrow exit opening 41 a, a funnel 42 and astuffer jet 43. The filter making apparatus includes a garniture, filterwrapping paper and wrapping paper-spool as well as other sections, notillustrated here. The first device 40 also includes a multi-regionmaterial positioning unit, generally indicated as 44. The multi-regionmaterial positioning unit 44 comprises a support block 45 which isattached to a support fin 41 c which extends vertically upwards from thetongue 41. The support block 45 is fixedly secured in place on the fin41 c of the tongue 41 by known connectors such as bolts, welds, etc.

The support block 45 includes five apertures 46 a-46 e extendingtherethough. A first aperture 46 a extends from the centre of the top ofthe support block 45 downwards to the tongue 41, and second and thirdapertures 46 b, 46 c extend from either side of the first aperture 46 aon the top of the support block 45 downwards to the tongue 41.Furthermore, fourth and fifth apertures 46 d, 46 e extend from the leftand right sides of the support block 45 respectively, laterally throughthe support block 45 to the tongue 41. Each aperture 46 a-e is inclinedat an angle so as not to be perpendicular to the central axis of thetongue 41 and to point slightly in the direction of the exit opening 41a, as shown in FIGS. 2 and 3. The tongue 41 includes a plurality ofapertures 47 a-47 e in its side wall extending through to the bore ofthe tongue 41, wherein each of the apertures 47 a-e is aligned with oneof the apertures 46 a-e in the support block 45, so as to provide aplurality of continuous passages though the support block 45 and throughthe lateral wall of the tongue 41 to the central bore of the tongue 41.

Five needles 48 a-e are provided, one disposed in each of the apertures46 a-e in the support block 45 which extend through the respectiveaperture 47 a-e in the tongue 41. Therefore, each needle 48 a-e extendsfrom outside the support block 45, though the support block 45 andthrough the wall of the tongue 41 and terminates within the bore of thetongue 41. The needles have internal passage diameters appropriate forcarrying fibres used to form the regions of the first filter materialused in the filter segments of the present invention.

An outer portion of each of the apertures 46 a-e in the support block 45is of a larger diameter than the inner portion proximate the tongue 41,and is threaded to receive a correspondingly threaded locking shaft 49a-e. The locking shafts 49 a-e each include a hollow bore (not shown)through which, in use, a respective needle 48 a-e extends, and thelocking shaft 49 a-e comprises a first continuous section at its lowerend, and a second, fingered section (not shown) at its upper end. Thefingered section is formed by a plurality of radial slots cut from thetop end of the locking shaft 49 a-e downwards and extending all the waythrough from the inner bore through to the outside of the locking shaft49 a-e. The remaining threaded sections of the ‘fingers’ are therebydefined between the slots and are deflectable in a radial direction ofthe locking shaft 49 a-e.

Also shown in FIGS. 2 to 4 are locking nuts 50 a-e which include aninternal thread corresponding to the external thread of the lockingshafts 49 a-e, and which are shaped to taper inwardly slightly so thatas each locking nut 50 a-e is threaded onto the fingered section of eachlocking shaft 49 a-e, the fingers are caused to be deflected inwardsinto the inner bore of the locking shafts 49 a-e. The inner bore of thelocking shaft is of the same diameter as that of the inner portion ofthe apertures 46 a-e which extend through the support block 45 and ofthe apertures 47 a-e which are formed in the lateral wall of the tongue41, so that needles 48 a-e fit snugly in the respective bores of thelocking shafts 49 a-e. It will therefore be appreciated that as thelocking nuts 50 a-e are threaded and tightened onto the respectivelocking shafts 49 a-e, they cause the fingers to be deflected inwards,and so when a needle 48 a-e is disposed in the inner bore of the lockingshaft 49 a-e, tightening the locking nuts 50 a-e causes the fingers tobe biased against the needle 48 a-e, thereby fixing the needle 48 a-e inthe chosen position.

It will be appreciated that the same effect may be achieved with anon-tapering locking nut having a constant thread diameter if the upperpart of the locking shaft comprising the fingers slightly tapersoutwards in a direction towards the tongue 41. Thereby, as the lockingnut is threaded further onto the locking shaft, the fingers would becaused to deform inwards, thereby binding against the needle 48 a-e tofix it in place relative to the locking shaft and thereby the tongue 41.

In use, a second fibrous filter material, for instance continuous fibresof crimped CA filter tow material, is conveyed through the bore of thetongue 41, and up to five individual supplies of the first fibrousfilter material, for instance continuous crimped fibrous PLA or othermaterial in thread or strand form, are fed through the needles 48 a-eand entrained in the flow of the second fibrous filter material, beingpulled through the needles 48 a-e as the second material passes throughthe tongue 41. The supply of the first fibrous filter material to theneedles 48 a-e can be achieved using a mechanical or electromechanicaldelivery device such as feed rollers, a feed conveyor, fluted feed drumor screw feeder (not shown) configured to feed the first fibrousmaterial from a continuous supply thereof. Such a mechanical orelectromechanical delivery device can have its speed adjusted so as tometer the first fibrous material into the second fibrous filter materialat an appropriate rate, for instance according to the speed of thesecond fibrous filter material passing through the tongue 41. Theemerging compressed filter rod which exits from the narrow exit opening41 a in the tongue 41 accordingly has up to five separate continuousregions of the first material therein extending in an axial directionthereof.

The exact position of the regions of first fibrous filter materialwithin the cross-section of the resulting filter rod can be accuratelydetermined and adjusted since the position of the first fibre regions inthe cross-section of the filter rod is dictated by the point within thetongue 41 at which the ends of the needles 48 a-e terminate. This can bealtered as described above, with each needle 48 a-e being independentlyadjustable to create a wide variety of patterns within the resultingfilter rod. The device 40 can accordingly be used to produce filter rodscontaining up to five regions of a first fibrous material along thelength of a second fibrous material. Filter rods having fewer than fiveregions of the first fibrous material therethrough can be produced bynot feeding supplies of the first fibrous material through one or moreof the needles 48 a-e.

FIGS. 5 to 7 are schematic illustrations of a second device 60 forinserting a first fibrous filter material into a second fibrous filtermaterial to produce a filter segment such as those illustrated in FIGS.1( a) to 1(d).

The second device 60 of FIGS. 5 to 7 is similar to the first device 40of FIGS. 2 to 4. The second device 60 in use, is connected to a filtermaking apparatus such as the KDF 2 apparatus produced by HauniMaschinenbau AG in Germany and is capable of producing a filter rod withup to five separate regions of a first fibrous filter material extendingthrough the cross-section of the filter formed from a second fibrousfilter material. The second device 60 comprises a tongue 61 having awide entrance opening 61 b and a narrow exit opening 61 a, a funnel 62and a stuffer jet 63. The filter making apparatus in which the seconddevice 60 is used includes a garniture, filter wrapping paper andwrapping paper-spool as well as other sections, not illustrated here.The second device 60 also includes a multi-region material positioningunit, generally indicated as 64. The multi-region material positioningunit 64 comprises a support block 65 which is attached to a support fin61 c which extends vertically upwards from the tongue 61. The supportblock 65 is fixedly secured in place on the fin 61 c of the tongue 61 byknown connectors such as bolts, welds, etc.

The support block 65 includes five apertures 66 a-66 e extendingtherethough, similar to the apertures 46 a-e of the support block 45 ofthe first device. The tongue 61 also includes a plurality of apertures67 a-67 e in its side wall extending through to the bore of the tongue61, wherein each of the apertures 67 a-e is aligned with one of theapertures 66 a-e in the support block 65, so as to provide a pluralityof continuous passages though the support block 65 and through thelateral wall of the tongue 61 to the central bore of the tongue 61.

Five needles 68 a-e are provided, one disposed in each of the apertures66 a-e in the support block 65 which extend through the respectiveaperture 67 a-e in the tongue 61. Therefore, each needle 68 a-e extendsfrom outside the support block 65, though the support block 65 andthrough the wall of the tongue 61 and terminates within the bore of thetongue 61. Similarly to the first device 40, the needles 68 a-e haveinternal passage diameters appropriate for carrying fibres used to formthe regions of the first filter material used in the filter segments ofthe present invention.

An outer portion of each of the apertures 66 a-e in the support block 65is of a larger diameter than the inner portion proximate the tongue 61,and is threaded to receive a correspondingly threaded locking shaft 69a-e. The locking shafts 69 a-e each include a hollow bore (not shown)through which, in use, a respective needle 68 a-e extends. The lockingshafts 69 a-e are similar to those of the first device 40.

Also shown in FIGS. 5 to 7 are locking nuts 70 a-e which are similar toand operate in the same way as the locking nuts 50 a-e of the firstdevice 40.

The second device 60 differs from the first device 40 by the orientationof the first, second and third apertures 66 a-c formed in the supportblock 65, and thereby the orientation of the plurality of continuouspassages though the support block 65 and through the lateral wall of thetongue 61 to the central bore of the tongue 61. Accordingly, the needles68 a-c respectively disposed in each of the first to third apertures 66a-c are correspondingly differently orientated.

It can be seen from FIG. 7 that the first, second and third needles 68a-c are arranged radially with respect to the central axis of the tongue61, as opposed to the first, second and third needles 48 a-c of thefirst device 40, which are all arranged with their respective axesparallel to each other. This alternative orientation of the first,second and third needles 68 a-c provides a different range of firstfibrous material region positions to be achieved within the filter rodand, in particular, allows closer positioning of these three firstfibrous material regions to each other and to the two other firstfibrous material regions from the fourth and fifth needles 68 d-e to beachieved. This is due to the fact that the radial orientation of thefirst to third needles 68 a-c means that when they are adjusted inwards,the ends of the needles 68 a-c converge towards the central axis of thebore of the tongue 68, rather than remaining the same spacing from eachother with respect to a horizontal line across the cross-section of thetongue 61.

In use, the second device 60 is operated in the same way as the firstdevice 40 described above. A second fibrous filter material, forinstance continuous fibres of crimped CA filter tow material, isconveyed through the bore of the tongue 61, and up to five individualsupplies of the first fibrous filter material, for instance continuouscrimped fibrous PLA or other material in the form of a thread or strandsand fed through the needles 68 a-e and entrained in the flow of thesecond fibrous filter material, being pulled through the needles 68 a-eas the second material passes through the tongue 61. The supply of thefirst fibrous filter material to the needles 68 a-e can be achievedusing a mechanical or electromechanical delivery device such as feedrollers, a feed conveyor, fluted feed drum or screw feeder (not shown)configured to feed the first fibrous material from a continuous supplythereof. Such a mechanical or electromechanical delivery device can haveits speed adjusted so as to meter the first fibrous material into thesecond fibrous filter material at an appropriate rate, for instanceaccording to the speed of the second fibrous filter material passingthrough the tongue 61. The emerging compressed filter rod which exitsfrom the narrow exit opening 61 a in the tongue 61 accordingly has up tofive separate continuous regions of the first material therein extendingin an axial direction thereof.

FIGS. 8 and 9 are schematic illustrations of a third device 80 accordingto an embodiment of the invention for inserting a first fibrous filtermaterial into a second fibrous filter material to produce a filtersegment such as that illustrated in FIG. 1( a).

FIG. 8 shows part of the third device 80 comprising a fibre insertsection 81. During operation of the third device 80, a second fibrousfilter material 82, in the form of cellulose acetate tow in the presentexample, is drawn through a set of conveying rollers (not shown), and iscompressed through a stuffer jet (not shown) and through the tongue 83of a garniture 84, where it is paper wrapped with a plugwrap 85 andsubsequently cut into segments by a cutter (not shown) to form filterrods.

FIG. 9 shows a cross section of the third device 80. The fibre insertsection 81 comprises a fibre feed tube 86, a venturi insert device 87and an insert tube 88. The insert tube 88 forms a fibre transfer path,in the present example from the venture insert device 87 to the tongue83, and may be bent so that it can be aligned longitudinally with thedirection in which the filter rod material 82 is conveyed in the tongue83. The position of the insert tube 88 may be adjusted using the inserttube adjustment wheel 88 a shown in FIG. 8. This allows the stream offibres to be positioned along the longitudinal axis of the second filtermaterial 84 or alternatively off-centre but parallel to the longitudinalaxis. The fibre insert section 81 also comprises first, second and thirdair jet inlets 89 a-c.

The feed tube 86 is configured to accept fibres of a first fibrousfilter material for insertion into a second fibrous filter material, thefirst fibrous material being supplied, for instance, in the form of athread or strands of the first fibrous material. The supply of the firstfibrous filter material to the feed tube 86 can be achieved using amechanical or electromechanical delivery device such as feed rollers, afeed conveyor, fluted feed drum or screw feeder (not shown) configuredto feed the first fibrous material from a continuous supply thereof.Such a mechanical or electromechanical delivery device can have itsspeed adjusted so as to meter the first fibrous material into the secondfibrous filter material at an appropriate rate, for instance accordingto the speed of the second fibrous filter material passing through thetongue 83. The emerging compressed filter rod which exits from thetongue 83 accordingly has a continuous region of the first materialtherein extending in an axial direction thereof.

FIG. 10 is an enlarged cross sectional view of the venturi device 87shown in FIG. 8. The venturi device 87 comprises a generally conicalblock 90 with an axial bore 91 having an inlet 92 that receives a supplyof fibres 93 from the feed tube 86 and an outlet 94 that supplies thefibres 93 into the insert tube 88.

The conical block 90 is received within a generally cylindrical housing95 with a conical end spaced from the block 90 to define a convergingair passageway 96 which opens into the insert tube 88 in the region ofthe outlet 94 of the bore 91.

The air supply passageway 96 is fed with compressed air from the threeair jet inlets 89 a-c, the first of which 89 a is shown in FIG. 10. Theair jet inlets 89 a-c are coupled to a compressed air or other gassource (not shown) and feed into respective longitudinal bores 97 a,bthat connect into the converging air supply passageway 96. Although thefirst, second and third jet inlets 89 a-c are fed with air, other fluidscould be employed, for example helium or nitrogen.

Fibres 93 are received from the feed tube 86 and are directed into theaxial bore 91. Compressed air from the first inlet 89 a is directedalong the longitudinal bore 97 towards the region 94 where the axialbore 91 and the longitudinal bore 97 converge. Compressed air from thesecond and third inlets 89 b, 89 c is also directed along correspondingrespective longitudinal bores (not shown) for these inlets towards theregion 94 where the axial bore 91 and those longitudinal bores converge.

During operation of the venturi device 87 the Venturi effect isexploited to propel the fibres 93 towards the filter rod material 92 asit is formed into filter rods.

FIG. 11 schematically illustrates the air flow in the venturi device 87during operation of the fibre insert section 81. As air is propelledfrom the first and second jet sources 89 a, 89 b through thelongitudinal bores 97 a, 97 b and into the insert tube 88, an area oflow pressure is created in the region 94 and insert tube 88. The fibres93 initially occupy an area of high pressure relative to this lowpressure region 94. A pressure gradient force is created that acts onthe fibres 93 and propels them into the insert tube 88 with a velocitygreater than if they were to be acted upon by the force due to gravityalone. This allows a high density of fibres 93 to be inserted into thesecond fibrous filter rod material. The insert tube 88 feeds into thetongue 83 of the third device 80 to insert fibres directly into thesecond fibrous filter material.

The position of the insert tube 88 may be adjusted relative to thelongitudinal axis of the filter rod under manufacture. In FIG. 9 theinsert tube 88 is bent however in other embodiments the insert tube 88may be straight. The fibres may be centred along the longitudinal axisof the filter rod or substantially parallel to but offset from thelongitudinal axis using the insert tube adjustment wheel 88 a shown inFIG. 8.

FIG. 12 is a cross sectional schematic view of a fourth device 100 inaccordance with a further embodiment of the invention for inserting afirst fibrous filter material into a second fibrous filter material toproduce a filter segment such as that illustrated in FIG. 1( a). Thefourth device 100 shown in FIG. 12 is similar to the third device 80shown in FIG. 8. However, the fourth device 100 shown in FIG. 12comprises a high flow vacuum pump 101 instead of the venturi insertdevice 87 shown in FIG. 8. The fourth device 100 also comprises a fibrefeed tube 102 and an exit tube 103.

The high flow vacuum pump 101 may be of a type known in the art formaterial transfer such as KVPDF High Flow Vacuum Pumps, or vacuum pumpssuch as the DF Series pumps supplied by Vaccon Company, Inc in the US.Compressed air enters the vacuum pump 101 through an air inlet 104 andflows cyclonically through a central tube 105 of the pump 101. Thecyclonic flow of compressed air produces a vacuum which can draw fibresfrom the feed tube 102, through the central tube 105 and into the exittube 103 to converge with the tongue 106 of the garniture (as shown inFIG. 8).

Compressed air can be supplied to the air inlet 104 at between 10 and 60Psi, for instance from 10 to 40 Psi, or preferably at about 30 Psi.

The feed tube 102 is configured to accept fibres of a first fibrousfilter material for insertion into a second fibrous filter material, thefirst fibrous material being supplied, for instance, in the form of athread or strands of the first fibrous material. The supply of the firstfibrous filter material to the feed tube 102 can be achieved using amechanical or electromechanical delivery device such as feed rollers, afeed conveyor, fluted feed drum or screw feeder (not shown) configuredto feed the first fibrous material from a continuous supply thereof.Such a mechanical or electromechanical delivery device can have itsspeed adjusted so as to meter the first fibrous material into the secondfibrous filter material at an appropriate rate, for instance accordingto the speed of the second fibrous filter material passing through thetongue 106. The emerging compressed filter rod which exits from thetongue 106 accordingly has a continuous region of the first materialtherein extending in an axial direction thereof.

FIG. 13 is a schematic illustration of a fifth device 110 according to afurther embodiment of the invention for inserting a first fibrous filtermaterial into a second fibrous filter material to produce a filtersegment such as those of the smoking articles illustrated in FIGS. 1( a)to 1(d).

The fifth device 110 of FIG. 13 includes components similar to thesecond device 60 of FIGS. 5 to 7. The fifth device 110 in use, isconnected to a filter making apparatus such as the KDF 2 apparatusproduced by Hauni Maschinenbau AG in Germany and is capable of producinga filter rod with up to five separate regions of a first fibrous filtermaterial extending through the cross-section of the filter formed from asecond fibrous filter material.

The fifth device 110 comprises a tongue 111 having a wide entranceopening 111 b and a narrow exit opening 111 a, a funnel 112 and astuffer jet 113. The filter making apparatus in which the fifth device110 is used includes a garniture, filter wrapping paper and wrappingpaper-spool as well as other sections, not illustrated here. The fifthdevice 110 also includes a multi-region material positioning unit,generally indicated as 114. The multi-region material positioning unit114 comprises a support block 115 which is attached to a support fin 111c which extends vertically upwards from the tongue 111. The supportblock 115 is fixedly secured in place on the fin 111 c of the tongue 111by known connectors such as bolts, welds, etc.

The support block 115 includes five apertures 116 a-116 e extendingtherethough, similar to the apertures 66 a-e of the support block 65 ofthe second device. The tongue 111 also includes a plurality of apertures(not shown) in its side wall extending through to the bore of the tongue111, wherein each of the apertures is aligned with one of the apertures116 a-e in the support block 115, so as to provide a plurality ofcontinuous passages though the support block 115 and through the lateralwall of the tongue 111 to the central bore of the tongue 111.

Five needles 118 a-e are provided, one disposed in each of the apertures116 a-e in the support block 115 which extend through the respectiveapertures in the tongue ill.

Therefore, each needle 118 a-e extends from outside the support block115, though the support block 115 and through the wall of the tongue 111and terminates within the bore of the tongue 111. Similarly to thesecond device 60, the needles 118 a-e have internal passage diametersappropriate for carrying fibres used to form the regions of the firstfilter material used in the filter segments of the present invention.

The fifth device also includes locking shafts 119 a-e and locking nuts120 a-e which are similar to and operate in the same way as those of thefirst and second devices 40, 60.

The fifth device 110 differs from the second device 60 in that a fibreinsert section is connected to each of the needles 118 a-e (althoughonly illustrated in respect of the fourth needle 118 d in FIG. 13). Thefibre insert sections correspond to the fibre insert section 81 of FIGS.8 and 9. The fibre insert section 130 connected to the fourth needle 118d comprises a fibre feed tube 131 and a venturi insert device 132. Theventuri devices 132 each comprise a generally conical block with anaxial bore having an inlet that receives a supply of fibres from thefeed tube 131 and an outlet that supplies the fibres into the needles118. Air supply passageways within the venture devices 132 are fed withcompressed air from the three air jet inlets 133 a-c. The venturi insertdevice 132 has its fibre stream outlet connected to the fourth needle118 d. The fourth needle 118 d forms a fibre transfer path, in thepresent example from the venture insert device 132 to the tongue 111.The fibre insert sections (not shown) connected to the first, second,third and fifth needles 118 a,b,c,e comprise corresponding features tothose of the fibre insert section 130 connected to the fourth needle 118d.

In use, the fibre insert sections operate in a corresponding manner tothe fibre insert section 81 of FIGS. 8 and 9, with the venturi device ineach section operating in the same manner as the venturi device 87described with reference to FIGS. 10 and 11. Accordingly, duringoperation of the fifth device 110, a second fibrous filter material, inthe form of cellulose acetate tow in the present example, is drawnthrough a set of conveying rollers (not shown), and is compressedthrough the stuffer jet 113 and through the tongue 111 of a garniture,where it is paper wrapped with a plugwrap and subsequently cut intosegments by a cutter (not shown) to form filter rods. At the same time,the venturi devices of each fibre insert section are operated bysupplying compressed air to the air inlets 133 a-c at between 10 and 60Psi, for instance from 10 to 40 Psi, or preferably at about 30 Psi suchthat the Venturi effect is exploited to propel fibres of a first filtermaterial into regions of the second filter material as it is formed intofilter rods.

FIG. 14 is a schematic illustration of a sixth device 140 according to afurther embodiment of the invention for inserting a first fibrous filtermaterial into a second fibrous filter material to produce a filtersegment such as that illustrated in FIG. 1( e).

The sixth device 140 of FIG. 14 is, in use, is connected to a filtermaking apparatus such as the KDF 2 apparatus produced by HauniMaschinenbau AG in Germany and is capable of producing a filter rod witha region of a first fibrous filter material extending through thecross-section of the filter formed from a second fibrous filtermaterial.

The sixth device 140 comprises a tongue 141, a funnel 142 and a stufferjet 143. The filter making apparatus in which the second device 140 isused includes a garniture, filter wrapping paper and wrappingpaper-spool as well as other sections, not illustrated here.

The sixth device 140 also includes a fibre insert unit 144 used tosupply a first fibrous filter material into the stuffer jet 143.Although only one fibre insert unit 144 is shown, two, three or morefibre insert units 144 can be used simultaneously. The fibre insert unit144, in the present example, comprises a DF Series vacuum pump assupplied by Vaccon Company, Inc in the US. The fibre insert unit 144includes a fibre insert tube 145 used to feed a first filter materialinto a second fibrous filter material flow 146 passing through thestuffer jet 143. The fibre insert unit 144 is mounted on an adjustablesupport member (not shown), which enables the position of the outlet ofthe tube 145 in relation to the stuffer jet 143 to be accurately set.The fibre insert unit 144 further comprises a fibre inlet 147 forreceiving a supply of first fibrous material and a compressed ait inlet148 for receiving a supply of compressed air, for instance at between 10and 60 Psi, for instance from 10 to 40 Psi, or about 30 Psi.

In use, the fibre insert unit 144 is supplied with compressed air andcreates an internal vacuum forcing a supply of a first fibrous filtermaterial as hereinbefore described into the stuffer jet 143.Accordingly, during operation of the sixth device 140, a second fibrousfilter material, in the form of cellulose acetate tow in the presentexample, is drawn through a set of conveying rollers (not shown), and iscompressed through the stuffer jet 143 and through the tongue 141 of agarniture, where it is paper wrapped with a plugwrap and subsequentlycut into segments by a cutter (not shown) to form filter rods. At thesame time, the fibre insert unit 144 is operated such that fibres of afirst filter material are transported into a region of the second filtermaterial as it is formed into filter rods.

The sixth device 140 has the advantage that the first filter material isinserted into the second filter material at a point upstream of thetongue 141 where the second filter material is relatively uncompressed.This can enable more diverse regions of first filter material to beinserted into a second fibrous filter material, forming shapes such asthe elongate sections described with reference to FIG. 1( e).

Although only one fibre insert unit 144 is used in the exampleillustrated in FIG. 14, multiple fibre insert unit 144 can be insertedinto the stuffer jet, for instance 2, 3, 4, 5 or 6 separate tubes, eachhaving corresponding adjustable support members.

Although a venturi device 132 has been used in the fifth device 110, ofFIG. 13, alternatively a high flow vacuum pump such as that describedwith reference to FIGS. 12 and 14 can be used in place of one or more ofthe venturi devices 132 (i.e. each of the first to fifth devices of thefifth device 110 of FIG. 13).

The embodiments of FIGS. 8 to 14, by using a fluid stream to insert afirst fibrous filter material into a second fibrous filter material caninsert the first fibrous filter material at a greater rate than the flowrate of the second fibrous filter material. Such feeding is referred toas over-feeding and can, for instance, be used to insert the firstfibrous filter material such that the ratio of the second fibrous filtermaterial rate:first fibrous filter material rate is in the range 1:1.1to 1:2, more preferably in the range 1:1.1 to 1:1.5.

In order to address various issues and advance the art, the entirety ofthis disclosure shows by way of illustration various embodiments inwhich the claimed invention(s) may be practiced and provide for superiorfilters, filter production methods, smoking articles and filterproduction devices. The advantages and features of the disclosure are ofa representative sample of embodiments only, and are not exhaustiveand/or exclusive. They are presented only to assist in understanding andteach the claimed features. It is to be understood that advantages,embodiments, examples, functions, features, structures, and/or otheraspects of the disclosure are not to be considered limitations on thedisclosure as defined by the claims or limitations on equivalents to theclaims, and that other embodiments may be utilised and modifications maybe made without departing from the scope and/or spirit of thedisclosure. Various embodiments may suitably comprise, consist of, orconsist essentially of, various combinations of the disclosed elements,components, features, parts, steps, means, etc. In addition, thedisclosure includes other inventions not presently claimed, but whichmay be claimed in future.

1. A filter segment for a smoking article, the filter segment comprisinga region of first fibrous filter material disposed at leastsubstantially within a region of second fibrous filter material, whereinthe first fibrous filter material comprises greater than 5% by volume ofthe total filter segment volume, the second fibrous filter material is aplasticised filter material and the first fibrous filter material is anon-plasticised filter material.
 2. A filter segment according to claim1, wherein the first fibrous filter material is disposed in a pluralityof regions of the filter segment.
 3. A filter segment according to claim2, wherein the plurality of regions can each comprise greater than 3% ofthe total filter segment volume.
 4. A filter segment according to claim1, wherein the first and second fibrous filter materials comprisecrimped fibres.
 5. A filter segment according to claim 1, wherein thefirst fibrous filter material comprises polylactide (PLA) fibres and/orthe second fibrous filter material comprises cellulose acetate fibres.6. A filter segment according to claim 1, wherein the first fibrousfilter material comprises from 5 to 60% by volume of the total filtersegment volume.
 7. A filter segment according to claim 1, wherein thefirst fibrous filter material comprises from 10 to 60% by volume of thetotal filter segment volume.
 8. A filter segment according to claim 1,wherein the first fibrous filter material comprises from 200 to 10,000fibres having a denier from 2 to 10 denier per filament.
 9. A filtersegment according to claim 1, wherein the region of first fibrous filtermaterial comprises a region extending longitudinally through the regionof second fibrous filter material.
 10. A filter segment for a smokingarticle, the filter segment comprising a region of first fibrousmaterial disposed at least substantially within a region of secondfibrous material, wherein the first fibrous material comprisespolylactide (PLA) fibres.
 11. A filter segment according to claim 10,wherein the second fibrous material comprises cellulose acetate (CA)fibres.
 12. A smoking article comprising a filter segment according toclaim
 1. 13. A method of producing a filter segment for a smokingarticle, the method comprising: feeding a supply of a first fibrousfilter material into a second fibrous filter material to form a filtersegment, controlling the delivery speed of the first fibrous filtermaterial into the second fibrous filter material to meter the firstfibrous material into the second fibrous filter material; forming aregion of first fibrous filter material disposed substantially within aregion of second fibrous filter material, wherein the first fibrousfilter material comprises greater than 5% by volume of the total filtersegment volume, the second fibrous filter material is a plasticizedfilter material and the first fibrous filter material is anon-plasticized filter material.
 23. The method of producing a filtersegment for a smoking article of claim 13 wherein the step of feeding asupply of a first fibrous filter material into the second fibrous filtermaterial includes adjusting a terminating end of needle within a tongueinto which the second fibrous material flows.
 14. A method according toclaim 13, further comprising applying a plasticiser to said secondfibrous filter material prior to feeding the supply of the first fibrousmaterial into the second fibrous filter material.
 15. A method accordingto claim 13, further comprising crimping said first and second fibrousfilter materials prior to feeding the supply of the first fibrousmaterial into the second fibrous filter material.
 16. A method accordingto claim 13, further comprising compressing said second fibrous filtermaterial to form a filter rod and feeding the supply of the firstfibrous filter material into the second fibrous filter material whilecompressing the second fibrous filter material to form the filter rod.17. A method according to claim 13, wherein the first fibrous filtermaterial is fed into the second fibrous filter material in a tonguesection of a filter making apparatus.
 18. A method according to claim13, wherein the first fibrous filter material comprises a thread offirst fibrous filter material.
 19. A method of producing a filter for asmoking article, the method comprising: generating a fluid stream; andtransferring a first fibrous material along a transfer path through thefluid stream, and then into a flow of a second fibrous filter material.20. A method according to claim 19, wherein said fluid stream isgenerated using air pressure.
 21. A method according to claim 19,wherein the first fibrous filter material is transferred into the flowof the second fibrous filter material in a tongue or stuffer jet sectionof a filter making apparatus.
 22. A device for inserting a first fibrousfilter material into a second fibrous filter material to form a filterfor a smoking article, the device comprising a pressure generator togenerate a fluid stream, wherein said first fibrous material istransferred through said fluid stream generated by said pressuregenerator along a transfer path and then into a flow of said secondfibrous filter material.